Wheel and method of and apparatus for making the same.



J. SLATTERY. WHEEL AND METHOD OF AND APPARATUS FOR MAKING THE SAME APPLICATION FILED MAR. 9 1911.

Patented Nov. 18, 1913.

3 SHEETS-SHEET 1.

J. SLATTERY. WHEEL AND METHOD OF AND APPARATUS FOR MAKING THE SAME.

APPLICATION FILED MAR.9, 1911.

3 SHEETS-SHEET 2.

Patented Nov. 18, 1913.

h 0 t m m H 1 J. SLATTERY. v WHEEL AND METHOD OF AND APPARATUS FOR MAKING THE SAME.

APPLICATION FILED MAR.9,1911. 1,079,030, Patented Nov. 18, 1913.

3 SHEETS-SHEET 3.

In van tor:

Attys UNITED. srarrns PATENT OFFICE.

JOHN SLATTERY, OF CHROME, NEW JERSEY,-

WHEEL ANDMETHOD. OF AND,APBAR;ATUS'FOR,M1Q.KIN,G THE 'SdME.

To all whom it may concern:

Be it known that I, JOHN SLATTERY, a c1t1 zen of the United States of America, and a resident of Chrome, in. the county of Middlesex and State of New Jersey, have invented a certain new and useful Wheel and Method of and Apparatus for Making the Same, of which the following is a specification.

My invention relates to metal wheels, specifically car wheels, and to methods of and apparatus for forging the same.

Wheels forged in accordance with my invention are free from the internal stresses which have militated against one-piece forged wheels formed according to prior methods; and my wheels have a forged rim which, because of the method of forging employed, is very tough and dense.

As a method my invention comprises forging the rim by pressure applied in a direction substantially perpendicular to the plane of the wheel, and in applying such pressure by a plurality of successive operations, each operatic-n affecting a relatively small portion only of such rim, and preferably affooting the rim only; that is to say, preferably the web and hub of the wheel are not pressed. to any material extent; to the contrary, the dies are so formed as to permit a certain amount of flow of the metal during the forging of the rib. By this method of forging wheels the wheel as a whole is permitted to contract freely in cooling, notwithstanding the mechanical operations being performed upon it, and thereby the presence of internal stresses in the finished wheel is obviated.

Other features of the method portion of my invention will be referred to hereinafter.

As an apparatus, my invention comprises a forging mill adapted to hold in place a cast or otherwise suitably formed blank for a car wheel or other wheel, and adapted to forge the rim of such wheel by a plurality of successive operations each affecting a relatively small portion of the rim of the wheel. the forging pressure being exerted in a direction substantially perpendicular to the plane of the wheel. And the apparatus portion of my invention comprises further. various details of construction, and arrangement of apparatus, as hereinafter described, and particularly pointed out in the appended claims.

The objects of my invention are to produce Specification of Letters Patent.

Application filed Match 9, 1911,

PatentedNov. 1831.913; SerieLNo, 613 258 dies being changed after one side of the wheel has been pressed preparatory to pressing the other side. It is more convenient, however, to describe the. process as carried on by two presses which,"in construction, may be entirely similar. In forging the blank, the said blank is placed flat in a suitable supporting and holding die. A complementary die, so formed as to leave therim portion of the wheel free, is brought into contact with the blank, so as to hold the latter in place, and then'one or more quick acting rim-forging dies are caused to act upon the rim portion of the wheel, in a direction substantially perpendicular to the plane of the wheel, such forging dies acting each time upon a relatively small portion only of the wheel rim; whereby full opportunity is given for the metal to flow as pres sure is exerted upon it. The wheel blank, as cast or otherwise formed in the first instance, is customarily provided with a. rib of excess metal in the region in which the forging die is to act, and by the action of such die this excess metal is pressed into the body of the rim, thereby condensing the metal of the rim, filling in all pipes, blow holes, etc., and giving to the rim great toughness and density. The wheel blank is then turned over and its rim forged in the same manner from the opposite direction, still further increasing the density and toughness of the metal.

In the accompanying drawings: Figure 1 show an elevation and partial section of a forging press such as may be employed according to my invention, the main portion of the press being shown in elevation, the forging dies being shown, however, in central vertical section and a wheel blank be ing shown in place between the dies. The dies as shown in Fig. 1 are dies adapted for the first forging operation. Fig. 2 shows a detail plan view of the mechanism for rotating the wheel blank step by step during the far described, is a familiar one.

forging operation. Fig. 3 is a View similar to Fig. 1, showin a' forging press with dies arranged for per 'orming the second forg ng operation. of the press shown in Flg. 1, the sectlon being taken on the line 00 -013 of Flg. 1.

Referring first to Fig. 1, numeral 1 designates the base plate of the press, and 2 designates the bottom or supporting die of the press. 3 designates a wheel blank in place in die 2. 4 designates an upper or holding die, mounted upon a cross head 5 arranged to slide up and down on column guides 6. 7 designates the top head of the press. 8 designates a ram cylinder and 9 the ram thereof, for pressing cross head 5 and die 4 downward, and 10, 10 designate cylinders and 11, 11 rams therefor for raising cross head 5 and die 4; rams 11 being connected to cross head 5 by means of tension rods 12. The press construction as so 13, 13 designate the cylinders of forging rams,

placed diametrically opposite each other,

and 14, 14 designate the forging rams working through uide passages 1n the upper head 7 of the press and provlded at their ends with dies 15 working through guide openings in the upper holding die 4. The wheel blank as first formed is customarily provided on one side with a rib 17 of excess metal and on its other side with a corresponding rib 18 of excess metal.

For convenience in rotating the wheel blank step by step, and also for convenience in removing the wheel blank from die 2, said die-is provided with a central opening 19 within which is located a lifting ram 20 having a collar 21 adapted, by hearing against the hub portion of the wheel blank,

to lift the same clear of the die 2. 22 designates cylinder of this lifting ram.

For rotating the wheel blank step by step, any suitable mechanism may be employed. I have indicated for the purpose, one of many such mechanisms, comprising a gear 23 on ram 20, an intermediate gear 24 meshing with gear 23, and a mutilated gear 25 operatively connected with a pinion 26 through ratchet mechanism 27 (Fig. 2) said gear 26 arranged to be rotated by a rack 28 operated by a .ram 29 and ram cylinder 30; the arrangement of the ratchet mechanism 27 being such that when the rack 28 moves outwardly and so rotates pinion 26, gear 25 is rotated through a complete revolution, thereby rotating gear 23 a distance depending upon the number of teeth of the gear 25 and the pitch-ratios of gears 25 and 23; a distance which, however,.is so regulated in design that the wheel blank. 3 is rotated at each such forward motion of the rack 28, through substantially the space covered by one of the forging dies 15, at each stroke.

It will be understood that during the back- Fig. 4 shows a horizontal sectlon ward motion of the rack 28 the ratchet pawl of ratchet mechanism 27 slips, the pinion 25 and parts driven thereby remainingstationar I The holdin dies 2 and 4 are preferably of segmental rm, as shown particularly in Fig. 4, leaving open spaces 31 between the segments. For this segmental construction of the holding dies there are various reasons, one of which is that it is desirable that the wheel blanks shall have as small surface contact with the holding dies as is consistent with firm holding of the blank, so that excessive cooling of the blank by contact with the dies may be avoided and that the wheel may contract naturally without being confined in such manner as to set up internal stresses. Another object of the segmental construction is, that the open spaces 31 permit the cleaning of the surface of the wheel blank, removal of mill scale, etc.

The press shown ip Fig. 3 is substantially identical with that shown in Fig. 1, except that the bottom or supporting die, here designated by numeral 32, has a form corresponding to that face of the wheel blank which was uppermost during the operation illustrated in Fig. 1, and except that the upperholding die, here designated by numeral 33, has a form corresponding .to the form of that face of the wheel blank which was down, in the operation illustrated in Fig. 1,

The forging dies 15 may be actuated by operating say at from fort-y to eighty strokes per minute. As is well known to steel workers, the action of a foregoing press is somewhat different from that of a hammer, causing less shock to the mental but exerting a sort of squeezing action which is particularly favorable for condensation of the metal forged, and for the flow of the forged metal in the immediate vicinity of the point of action of the forgoing die. The action of a hammer, unless it be ,a very heavy hammer, and therefore slow acting, is apt to be confined largely to the immediate vicinity of the point of location of the blow; whereas a press-actuated die, operating even at the same speed, but operating somewhat more gently, seems to spread to a' greater depth through the metal acted upon, and does not and the forging die or dies 15 are caused.

to act upon the rim portion of the wheel blank, driving the excess metal 17 into the body of the rim, condensing the metal of the rim and filling in any pipes, blow holes, etc, that may be therein. A plurality of such forging dies 15 may act simultaneously upon dlfierent portions of the rim. In

the structure shown in Fi 1 I have illustrated two such dies 15 acting upon diametrically opposite portions of the wheel blank. After each stroke of the forging die or dies 15, the wheel blank is raised slightly from the die 2, by the action of the elevating ram 20, and is rotated 21 short distance by the rotating mechanism operated by the ram 29,

, so that each succeeding blow of the forging die or dies 15 acts upon a different portion of the wheel rim, a portion removed from the portion previously acted upon by just about the width of the face of the forging die. \Vhen the entire rim of the wheel has been acted upon in this manner, the holding die 4 is raised by means of the rams 11, the wheel blank 3 is lifted from the die 2 by means of ram 20, and is removed from the press, turned over, and placed on the die 32 of the press shown in Fig. 3, the die 33 of that press is lowered and the opposite edge of the rim of the wheel is acted upon in a similar manner by the forging dies 15 of such second press, forging into the body of the rim of the wheel the excess metal 18.

As appears from the drawings, the construction of the press as shown in Figs. 1 and 3, is substantially identical. Therefore, instead of employing two presses, a single press might be employed for both operations; but this would involve the changing of the dies in the press, and this in turn would involve the cooling and reheating of the wheel blank. It is desirable that the forging of both sides of the wheel blank shall be conducted at one heat; for which reason it is preferable to employ two forging presses placed in proximity to each 1 other, so that a wheel blank when removed from the first press, may be transferred quickly to the other press.

The die 4 of the first press, and the die 33 of the second press, have such clearance with respect to the rim of the wheel blank, that slight flow of the forged metal is permitted. It is not ordinarily necessary to press the hub and web of the wheel, and therefore the press cylinder 8 and ram 9 of each press are customarily designed to exert only such pressure as is necessary to hold the Wheel blank in place and prevent deformation thereof; a pressure, usually of from two hundred to four hundred tons. By providing a plurality of forging dies 15 and operating means therefor, placed diametrically opposite each other, and by causing such forging dies to act substantially simultaneously, not only is the operation of forgtortion of the wheel blank in forging is substantially obviated, since the wheel blank is operated upon simultaneously at diametrically opposite points. Since the action of the forging dies 15 is to drive the wheel blank against the supporting dies :2 and 32, the faces of the rim are perfected as a result of the forging operation, and are rendered truly concentric to the hub of the wheel. If desired the tread surface of the forged wheel may be trued as by grinding, after the forging operation is completed.

Since our wheels are made of various different diameters, different sized dies, 2,4,32 and 33 will be required for the different sizes of wheels to be made; and in the construction shown customary provision is made for the removal of dies from the press and the substitution of other dies. Relocation of the cylinders and rams of the forging dies is not necessary, however, because the line of action of the forging dies may be adjusted, within customary ranges of size of car wheels, by locating the forging dies 15 (removable as shown from the forging rams 14) more or less eccentric with respect to said rams, as conditions may require.

The effect of the forging operations described, upon the rim of the wheel, is to condense and toughen the metal of the rim, making the rim portion of the wheel much harder than it would be otherwise and without correspondingly or materially increasing the hardiness of the hub portion.

Heretofore forged car wheels have been made by various processes. In some cases they have been forged up from flat stock; but wheels so forged are known to be subject to the objection that the rim of the wheel can be little, if any, harder than the hub of the wheel. It is necessary that the hub of the wheel shall be fairly soft,'in order that it may be bored For the reception of the axle; and this condition limits the degree of hardness permissible in the metal of wheels forged from flat stock. Moreover, the forging of car wheels and the like, from fiat stock, involves a number of successive operations, and usually involves several reheatings of the blank, and involves excessive distortion of the metal from its original' section. Attempts have also been made to produce car wheels from east blanks, by

'pressing, hammering and rolling, but as I duce a large number of wheels of exactly is rolled, or wherein the metal of the wheel blank is greatly distorted by elaborate forging operations, since, for success in rolling or for success in forging operations involving much distortion of the original wheel blank, use of a relatively ductile and therefore low-carbon steel, is essential. Moreover, in prior methods of forging. or pressing the entire wheel, or even the entire rim, in one operation, the free contraction of the wheel is interfered with, resulting in the setting up of enormous internal stresses. The web of the wheel, being the thinnest portion of the wheel, necessarily tends to set first. If the rim be confined, as it will be if the entire rim or the greater part thereof be held between forging dies, the rim is prevented from following the web during. the contraction of the latter, and excessive stresses are set up between the rim-andthe web, which stresses are enhanced as the rim itself cools. Much the same is true with re spect to the web and hub.

By the process herein described I am able" to produce wheels from east blanks which have a relatively tough, dense and hard rim portion, and a relatively soft hub portion; and the wheels thus produced are true to size and shape and are of uniform quality, provided the quality of the metal from which they are formed remains uniform.

By the process herein described, since a portion only of the rim is held at any one time, and since this portion is held for a brief instant only, the wheel is permitted to contract and set as a whole, practically the same as it would if it were allowed to cool without being subjected to any mechanical operations whatever during the cooling. Thereby I am able to produce wheels which are free from internal stresses; something which I believe has never before been accomplished in the case of a one-piece forged wheel. As a result the wheel is entirely free from brittleness due to internal stresses.

The process herein described is not limited to the making of car wheels, but is equally applicable for various other types of wheels, such for wheels.

What I claim is 1. A metal wheel comprising a hub portion, a rim portion, and means connecting same, all formed in one piece, the rim portion compressed in a direction substantially parallel to the axis of the wheel, the remainder of the wheel beingsubstantially uncompressed. v 2.. A metal car wheel comprising a hub portion, a rim portion, and means connecting same, all formed in one piece, the rim porexample as blanks for gear tion composed of hard highly condensed forged metal, the hub portion composed of soft-er less condensed metal.

3. A process of forging metal car wheels which comprises compressing the rim portion in a direction approximately parallel to the axis of the wheel, by a succession of operations each afiecting a portion only of the rim of the wheel.

4. A process of forging metal car wheels which comprises compressing the rim portion in a direction approximately parallel to the axis of the wheel, by a succession of operations each affecting a portion only of the rim of the wheel, and under conditions permitting spreading of the metal so compressed, in another direction.

5. A process of forging metal car wheels which comprises compressing the rim portion whilehot, by a succession of operations each affecting a portion only of rim of the wheel, and each affecting a different portion of such rim, the wheel as a whole being permitted to contract freely during the forging, whereby the setting up of internal stresses is avoided.

6. A process of forging metal wheels, comprising forming a metal blank having excess metal on one or both of the side faces of its approximately perpendicular to the plane of the wheel, the hub portion being subjecged to less pressure.

8. A process of formlng metal wheels whlch comprises forming a one piece metal blank having in a single integral structure a rim portion, a hub portion and connecting means, and condensing the metal of the rim portion by pressure exerted in a direction approximately perpendicular to the plane of the wheel and exerted by a plurality of successive operations, each operation affectin a relatively small portion only of such rim, t e hub portion being subjected to less pressure.

9. A process of forging metal wheels comprising compressing the metal rim by a series of successive pressure operations, each affecting a relatively small portion only of such rim, pressure being applied first to one side of the rim, and then tothe other side thereof.

10. Apparatus for forging metal wheels comprising wheel-holding means and a pressure die arranged to act laterally with respect to a wheel blank held by such holding means, upon the rim portion of such blank, and to act on such rim by a plurality of operations each affecting a portion only of t e rim, and means for actuating such pressure die.

11. Apparatus for forging metal wheels comprising wheel-holding means provided with an aperture, in registry with the position for the rim of a wheel held in such holding means, a pressure die arranged to work in such aperture and to act laterally upon a wheel blank held by such holding means, and means for actuating such pressure die.

12. Apparatus for forging metal Wheels comprising wheel-holding dies, fluid-pressure-actuated means for separating said dies and bringing them together at will, a pressure die arranged to act laterally upon a portion of a wheel held in said holding dies, and fluid pressure actuated means for operating said pressure die.

13. Apparatus for forging metal wheels comprising wheel-holding dies, fluid-pressure-actuated means for separating said dies and bringing them together at will, a pressure die arranged to act laterally upon a portion of a wheel held in said holding dies, fluid pressure actuated means for operating said pressure die, and means for rotating intermittently a wheel located in said holding means.

14. Apparatus for forming metal wheels comprising upper and lower wheel holding dies, means for raising and lowering the upper holding die, a pressure die arranged to act upon the rim portion of a wheel resting upon said lower die, means for rotating intermittently a,\vheel so held, and means for raising a wheel so held from said lower die.

In testimony whereof I have signed this specification in the presence of two subscribing witnesses.

JOHN SLATTERY.

Witnesses:

F. Mona CANDA, WILLIAM J. LAWLOR. 

